Cement KPIs - 2009

8/17/2019 Cement plant Key performance Indicators
MMP
GLOSSARY
2009
NB: This Glossary presents the indicators specific to MMP.

For the full scope of Technical Indicators please also
consult the CKHC Glossary.
Copyright 2007-2009 Lafarge SA – DPC/ Confidential 1/32
http://slidepdf.com/reader/full/cement-plant-key-performance-indicators 1/32
ACCOUNTING
Total Power expenditure LMU AC000X
Expenditure in finish grinding LMU AC400X
Total Heat expenditure LMU AC761X
Expenditure Up to clinker LMU AC762X
Average Specific Power Cost LMU/Mwh AR001X
Expenses (Finish Grinding) / t cement LMU/t AR407X
Average Specific Heat Cost LMU/GJ AR607X
PRODUCTION COST ( cement costing)

Average Unitary Technical Cost/t: (all types of cement) LMU/t CE005X
Combustibles expenses/t: (by type of cement) LMU/t CE007X
Power expenses/t: (by type of cement) LMU/t CE008X
Maintenance cost per tonne of cement produced LMU/t CE016X
Energy Cost per tonne of cement LMU/t CE042X
CONSUMPTION RATIO
Specific Heat consumption: raw mix drying to clinker (Up to MJ/t CR002X
clinker, all types of clinker, all types of raw mix, all types of fuel)
Specific Heat consumption: burning (all kilns, all types of clinker, all MJ/t CR003X
types of fuel)
Specific Heat consumption: kiln (by kiln, all types of clinker, all MJ/t CR005X
types of fuel)
Heat cons : raw mix drying (Raw mix preparation, all types of fuel) GJ CR014X
Heat consumption : Total (All types of fuel) GJ CR015X
Heat cons : burning (all kilns, all types of clinker , all types of fuel) GJ CR017X
Heat consumed GJ CR019X
% Standard/high quality coal % CR029X
Pet Coke percentage: (all kilns, all types of clinker) % CR030X
Fuel oils percentage: (all kilns, all types of clinker) % CR031X
High viscosity fuel percentage: (all kilns, all types of clinker) % CR032X
Natural gas percentage: (all kilns, all types of clinker) % CR033X
% low quality coal % CR034X
Alternative fuels percentage: (all kilns, all types of clinker) % CR035X
Power consumption /Tonnage : (by crusher, all products) kWh/t CR037X
Power consumption/Tonnage: (by raw mill, all types of raw mix) kWh/t CR040X
Power consumption/Tonnage: (by kiln, all types of clinker) kWh/t CR044X
Power consumption /Tonnage: (by finish mill, all types of cement) kWh/t CR048X
Power consumption /Tonnage: (Finish grinding, all types of kWh/t CR050X
cement)
Power consumption / T Solid fuels: (by coal mill, all types of solid kWh/t CR051X
fuel)
Power consumption /Tonnage produced: (Up to clinker, all types kWh/t CR054X
of clinker)
Power consumption /Tonnage produced :(Up to cement, all types of kWh/t CR056X
cement)
Power consumption : (by crusher , all products) Mwh CR057X
Power consumption : (by raw mill , all products) Mwh CR060X
Power consumption : (by kiln , all types of clinker) Mwh CR064X
Power consumption : (by Finish mill , all products) Mwh CR068X
Power consumption : (Finish grinding, all products) Mwh CR070X
Power consumption : (Fuel preparation, all products) Mwh CR072X
Power consumption : (Up to clinker, all types of clinker) Mwh CR074X

Power consumption : (Up to cement , all types of cement) Mwh CR076X
C/K - Additive coefficient: (by product and/or all products) n CR077X
Quantity consumed of clinker : (all types of kk, all types of cement) t CR096X
PRODUCTION COST ( clinker costing)

Average Unit Technical Cost: (all types of clinker) LMU/t KK001X
Maintenance expenses/t: (by type of clinker) LMU/t KK015X
MAINTENANCE
MCI - Maintenance cost index: (all types of cement) n MA001X
Maintenance reference cost LMU/t MA002X
Equipment Failure Rate Burning Line (by kiln, all products) % MA074X
PRODUCTION ACTIVITY
Number of Cement types n PA007X
Quantity produced: (by equipment, all types of Cement) t PA012X
Quantity produced : (all equipments , by type of Cement) t PA014X
Quantity produced (all types of Cement) t PA015X
Cement in bulk percentage : (all types of cement) % PA018X
Quantity produced: (by kiln, all types of Clinker) t PA019X
Quantity produced (all types of Clinker) t PA021X
Quantity produced : (all kilns, by type of Clinker) t PA022X
Quantity received: (all types of clinker) t PA023X
Quantity produced: (by raw mill, all types of raw mix) t PA026X
Quantity produced : (all types of Crushed products) t PA028X
Quantity shipped: (all types of clinker) t PA035X
Quantity shipped : (all types of cement, all types of shipments) t PA040X
Quantity shipped : (all types of cement in bags) t PA042X
Quantity shipped : (all types of cement in bulk) t PA044X
Cement in bags shipped percentage: (all types of cement) % PA045X
T- Available Opening hours h PA087X
t1 - Effective Operating time : (for kilns only, by product) h PA088X
t1 - Effective Operating time : (by equipment except kilns) h PA089X
t2 - Cumulated Hours of Shutdowns on Incidents : (by equipment) h PA091X
t4 - Circumstance downtime h PA093X
MTBF - Mean Time Between Failure: (by equipment) h PA096X
NSFI- Incident stoppages: (by Equipment) n PA098X
NSFI- Incident stoppages: (All kilns) n PA104X
Quantity produced: (by equipment, all types of Fuel prepared) t PA111X
Potential Production t PA133X
MTBF - Mean Time Between Failure: (all kilns) h PA121X
PEOPLE
Site headcount: (Internal population) (Average) n PE002X
Manufacturing population: (Average) n PE003X
Hours worked Cement Division activity: (Lafarge employees) h PE021X
Hours worked Cement: (all types of cement) h PE022X
Hours worked Clinker: (all types of clinker) h PE023X
Hours worked : (Finish Grinding, all types of cement) h PE024X
Manpower productivity h/t PE029X
Total overtime hours h PE031X
Total regular hours h PE033X
Overtime % PE036X
Hours worked : (Packing & shipping, all types of cement) h PE052X
PERFORMANCE RATIO
KFUI - Kiln feed uniformity index: (by kiln, by main type of clinker) n PR002X
KFUI - Kiln feed uniformity index: (all kilns, by main type of clinker) n PR003X
UI(SO3) - Clinker uniformity index: (by kiln, by main type of clinker) n PR004X
UI(SO3) - Clinker uniformity index: (all kilns, by main type of n PR005X

clinker)
s'(FCaO) - Clinker Free Lime standard deviation : (all kilns, by main % PR009X
type of clinker).
FCaO - Free lime Uniformity Index : (by kiln, by main type of % PR010X
clinker).
FCaO - Free Lime Uniformity Index : (all kilns, by main type of % PR011X
clinker).
m(FCaO) - Clinker Free Lime average : (all kilns, by main type of % PR013X
clinker).
Utilization factor: (by crusher) % PR015X
Utilization factor: (by Raw mill) % PR017X
Utilization factor: (by Solid fuel mill) % PR019X
Utilization factor: (by Kiln) % PR021X
Utilization factor: (by Finish mill) % PR023X
Operating time in automatic OTA: (by equipment) % PR028X
Automation Confidence Month :(by kiln) h PR030X
Reliability factor: (by crusher) % PR033X
Reliability factor: (by Raw mill) % PR035X
Reliability factor: (by Solid fuel mill) % PR037X

Reliability factor: (all Kilns) % PR038X
Reliability factor: (by Kiln) % PR039X
Reliability factor: (by Finish mill) % PR041X
Performance factor: (by Kiln) % PR048X
Rated Capacity: (by Kiln) t/24h PR050X
Output: (by Kiln, all types of Clinker) t/24h PR053X
Output: (by Finish mill, all types of product) t/h PR057X
Output: (by Solid fuel mill, all types of Solid fuel) t/h PR061X
Output: (by Raw mill, all types of Raw mix) t/h PR063X
Fineness: (by mill system, by product) FU PR069X
Output : (Crushing, all types of crushed products) t/h PR073X

Automation Confidence Month : (by raw mill) h PR074X
Process Failure Rate Burning Line (by kiln, all products) % PR102X
Automation Confidence Month : (by Coal mill) h PR103X
Operating hours in Automatic : (by equipment) h PR105X
QUALITY
28 day strength: (by type of cement) Mpa QU004X
28 day strength uniformity (by type of cement) Mpa QU009X
28-day strength Uniformity "main types of cements" MPa QU014X
IQP (product quality indicator) % QU026X
SAFETY
Reference : Health & Safety Governance Standard – Incident Reporting and Investigation
New in 2009:
INPUT file (Actual and Budget)

1) FUEL MIX section:
Petcoke (like coal)quality

- high/standard was split in see
coal; two categories - twoCR229X
BRS definition entry lines
- low quality coal; see BRS definition: CR230X
2) KILN section
- Circumstantial stoppages - new entry line
See BRS definition: PA093X
- Potential Production - calculated indicator
See BRS definition; Indicator used for the calculation of Reliability Factor: Plant
level
- Process indicators: KFUI, KSUI, FLUI - no more YTD calculation
Please enter in the "MANUAL CUMUL ENTRY" the year-to-date value.
3) Environment
- Direct CO2 emissions; tons of CO2 - clarification of an existing indicator
EN004X
- CO2 emissions - change of the calculation formula see BRS definition EN049X
CO2 emissions : direct CO2 / (PA015X + PA021X - (PA015X / CR077X)) * 1000
REPORT file (Actual and Budget)
4) GENERAL section
- Burning line Reliability Factor: new formula
Consolidated via Potential Production
5) PRODUCTION AND PROCESS section

- Process Failure rate: new formula
6) MAINTENANCE section
- Kiln Equipment failure rate: new formula
MMP database
7) Consolidated mills Utilisation Factor: new formula (raw and cement mills)
Include mills with ZERO operation hours in a months (via YTD hourly output)
AC000X LMU
Cost of power
Cost/MWh P-Plant
Total power expenses for cement in bin manufacturing.
For plants with several main substations with distinct contracts, this definition applies separately to each main
substation for the shops serviced
(Example: Quarry with a dedicated substation). For plants generating their own power, resources used to
produce this power should only appear once:
- Either in the cost of MWh, but only if the resources used are completely known. In this case not only expenses
but also related resources (hours, population, MJ, etc...) will be charged to MWh and not to clinker or cement.
- Or in Fuel, labor, etc...for the production or clinker or cement. In such a case, the expense for this production
of MWh is nil. In both cases, the Power expenses is calculated as: (Expense of MWh production+Purchase of
MWh-Sale of MWh).
Pierre Tonin
AC400X LMU
Finish Grinding expenses :
Finish Grinding 4- Finish Grinding
All expenses (60xxxx to 69xxxx) incurred in Finish grinding (CC 4xx).
ref :Chart of accounts Tree Structure.

AC401X +AC402X
Pierre Tonin
AC761X LMU
Heat expenses : (all types of fuel)
Fuel 6 – Fuel preparation
Expenses of heat consumed all types of fuel during a given period.

Pierre Tonin
AC762X LMU
Up to Clinker expenses : (Up to Clinker)
Up to clinker K – Up to clinker
All expenses (60xxxx to 69xxxx) incurred up to Clinker.
ref :Chart of accounts Tree Structure.
Pierre Tonin
AR001X LMU/Mwh
Average Specific Power Cost
Cost/MWh P-Plant
Total power expenses for cement in bin manufacturing divided by the corresponding quantity of MWh
consumed during a given period.
For plants with several main substations with distinct contracts, this definition applies separately to each
main substation for the shops serviced (Example: Quarry with a dedicated substation). For plants
generating their own power, resources used to produce this power should only appear once: - Either in the
cost of MWh, but only if the resources used are completely known. In this case not only expenses but also
related resources (hours, population, MJ, etc...) will be charged to MWh and not to clinker or cement. - Or in
Fuel, labor, etc...for the production or clinker or cement. In such a case, the expense for this production of
MWh is nil.
= Power expenses/Power consumed In both cases, the average cost of MWh used is calculated as :
(Expense of MWh production+Purchase of MWh-Sale of MWh) / MWh used (CE008X divided by CR056X)
multiplied by 1000
Benchmark with plants in the same economic group - all plants with similar economy based on labor costs.
Pierre Tonin
AR407X LMU/t
Expenses(Finish Grinding) / t cement
4-Finish Grinding
All expenses incurred in Finish grinding stage (CC 4xx) divided by produced quantities of cement in bin during
a given period.
CE005X - (KK001X/CR077X)
Pierre Tonin
AR607X LMU/GJ
Average Specific Heat Cost
Cost/GJ P - Plant
The average specific heat cost or cost of fuel mix is the average heat expense of the different fuels used for
clinker production, weighted by the % of heat consumed.
For plants generating their own power, fuels already included in the power cost can not be taken into
account. The costs of the in-house power plant should only appear once in the clinker production cost: either
as fuel and fuel costs, or in the power cost.
From 2006, this indicator will be also used for the calculation of the Alternative Fuels gross savings (see
PR086X).
= Sum (LMU/GJ * %) / 100 = Average heat expenses/GJ heat consumed (all types of clinker)
Benchmark with plants in the same economic group - all plants with similar economy based on labor costs
Pierre Tonin
CE005X LMU/t
Average Unitary Technical Cost/t : (all types of cement)
Cem Total C-Up to Cement
Average Technical Unitary costs of each type of Cement, weighted by the quantity produced of each type of
Cement during a given period.
Excludes: head office overhead, sales, depreciation, financial expenses, inventory change adjustments and
the impact of purchased clinker ,Cement silos costs.
CE020X + CE019X + CE015X + CE010X + CE007X + CE008X + CE009X +CE021X Benchmark with plants in
the same economic group - all plants with similar economy based on labor cost
Pierre Tonin
CE007X LMU/t
Combustibles expenses/t : (by type of cement)
Cem Fuel C-Up to Cement
Unitary Fuels Cost (Cost line 100) for Cement (by type of Cement). All fuels consumed in Cement preparation,
regardless of their destination during a given period.
For plants generating their own power, fuels included in the power generation cost are not to be taken into
account. The costs of the in-house power plant should only appear once in the Cement cost: either in fuel
consumption and fuel costs, or in the power cost. These expenses include the expenses of upstream
products.
Is calculated by: ((fuel expenses/t clinker) / add coeft ) + cost for cement additives drying or Costing cost
line 100 for cement.
Pierre Tonin
CE008X LMU/t
Power expenses/t : (by type of cement)
Cem Power C-Up to Cement
Unitary Power Cost (Cost line 110) for Cement (by type of Cement). All power consumed for Cement
manufacturing during a given period.
For plants
under Fuel,generating
Manpower, their own power,
Supplies etc. orpower
under plant
Power.expenses
should only appear once: either broken down
Is calculated by: (cost for KK / add coeft) + cost for grinding (KK004X divided by CR077X) + CR050X x
AR001X
Pierre Tonin
CE016X LMU/t
Maintenance cost per tonne of cement produced
Cem Maint C-Up to Cement
Maintenance expenses (FI2009X) per tonne of cement (silo) produced, according to the costing methodology
For CKHC and Management Reportings, the cascade is limited to clinker/cement (i.e. it does not take into
account opening inventory and purchases of clinker)
Refer to "Lafarge Cement Business Costing - Concepts & Methodology, V5" Benchmark with plants in the
same economic group - all plants with similar economy based on labor cost
Pierre Tonin
CE042X LMU/t
Energy Cost per tonne of cement
C-Up to Cement
Fuels and Power costs per tonne of cement
CE007X + CE008X Benchmarked across the entire Cement Division

Pierre Tonin
CR002X MJ/t
Specific Heat consumption : raw mix drying to clinker (Up to clinker, all types of
clinker, all types of raw mix, all types of fuel)
MJ raw mixes drying /t KK K-Up to Clinker
Heat Consumption (Low Heat Value) for drying raw mixes (all types of raw mix) divided by produced tonnage
of clinker (all types of clinker) during a given period.
Does not include heat recovery and heat supplied by the waste gas of the kiln.
Jacques Denizeau
CR003X MJ/t
Specific Heat consumption : burning (all kilns, all types of clinker, all types of fuel)
MJ/t Burn allKK 3-Burning
Heat Consumption (Low Heat Value) of all kilns, divided by produced tonnage of clinker (all types of clinker)
during a given period.
Includes useful heat value of the raw mix, but not that used for fuel preparation.
Average of each "Specific Heat Consumption : kiln" (CR005X) weighted by the produced tonnage of clinker
(all types of clinker).
Jacques Denizeau
CR005X MJ/t
Specific Heat consumption : kiln (by kiln, all types of clinker, all types of fuel)
MJ/t kiln allKK 3-Burning
Heat Consumption (Low Heat Value) of a kiln, divided by produced tonnage of clinker (all types of clinker)
during a given period.
Includes 100% of low heat value of the raw mix, but not that used for fuel preparation
Jacques Denizeau
CR014X GJ
Heat consumption : raw mix drying (Raw mix preparation, all types of fuel)
Raw mix drying 2 – Raw Mix Preparation
Heat Consumption (Low Heat Value) for drying raw mixes is the total heat consumed for drying the raw mixes,
excluding heat of the waste gas of kiln.
Does not include heat recovery.
Jacques Denizeau
CR015X GJ
Heat consumption : Total (All types of fuel)
Total P – Plant
Total heat Consumption (Low Heat Value) during a given period .
Does not include heat recovery.
Jacques Denizeau
CR017X GJ
Heat consumption : burning (all kilns, all types of clinker , all types of fuel)
Burning 3- Burning
Heat Consumption (Low Heat Value) of all kilns is the total heat consumed for the whole clinker production (all
types of clinker during a given period.
Fuel preparation excluded
Jacques Denizeau
CR019X GJ
Heat consumption : kiln (by kiln, all types of clinker, all types of fuel)
Heat cons. burning 3- Burning
Heat Consumption (Low Heat Value) of a kiln is the total heat consumed for the whole production of clinker (all
types of clinker ) for a specific kiln during a given period
Jacques Denizeau
CR029X %
% Standard/high quality coal
% high quality coal K-Up to Clinker
Standard/high quality coal MJ (Low Heat Value) consumed (all kilns, all types of clinker) divided by Heat
consumption (all kilns, all types of clinker). Standard/high quality coal has a low heat value (LHV) above
22.5GJ/tonne (dry basis).
High grade coal only. Includes Fuels for Raw mix drying, clinker burning, fuel preparation and other consumption
chargeable to clinker, but not cement additives drying.
High grade coal only, whose low heat value is above 22.5GJ/tonne (dry basis).
Includes Fuels for Raw mix drying, clinker burning, fuel preparation and other consumption chargeable to clinker,
but not cement additives drying.
Sergiu Meauta
CR030X %
Pet Coke percentage : (all kilns, all types of clinker)
% Coke K-Up to Clinker
All Pet coke types MJ (Low Heat Value) consumed (all kilns, all types of clinker) divided by Heat consumption
(all kilns, all types of clinker).
Includes Fuels for Raw mix drying, clinker burning, fuel preparation and other consumption chargeable to
clinker
Sergiu Meauta
CR031X %
Fuel oils percentage : (all kilns, all types of clinker)
% Oil K-Up to Clinker
All Fuel oils types MJ (Low Heat Value) consumed (all kilns, all types of clinker) divided by Heat consumption
(all kilns, all types of clinker).
Fuel oils type doesn't include light oil and high viscosity products. Includes Fuels for Raw mix drying, clinker
burning, fuel preparation and other consumption chargeable to clinker
Sergiu Meauta
CR032X %
High viscosity fuel percentage : (all kilns, all types of clinker)
% HVF K-Up to Clinker
All High viscosity fuel types MJ (Low Heat Value) consumed (all kilns, all types of clinker) divided by Heat
consumption (all kilns, all types of clinker).
Pitch, bottom products.

Sergiu Meauta
CR033X %
Natural gas percentage : (all kilns, all types of clinker)
% Gas K-Up to Clinker
All Natural gas types MJ (Low Heat Value) consumed (all kilns, all types of clinker) divided by Heat
Includes Fuels for Raw mix drying, clinker burning, fuel preparation and other consumption chargeable to
clinker
Sergiu Meauta
CR034X %
% low quality coal
% low quality coal K-Up to Clinker
Includes low quality coal used in clinker manufacturing, whose low heat value (LHV) is below 22.5 GJ/tonne (dry
basis).
The lower quality coal comprises all subbituminous coals, i.e., those that are more abundant than high quality: all
types of lignites and also "schlamm/waste coal". "Schlamm", a by-product of coal production, sometimes stored in
basins or in piles near the production sites, must be reported under this category.
It includes fuels for raw mix drying, clinker burning, fuel preparation and other consumption chargeable to clinker.
All low quality coal MJ (Low Heat Value) consumed (all kilns, all types of clinker) divided by Heat consumption (all
kilns, all types of clinker).
Sergiu Meauta
CR035X %
Alternative fuels percentage : (all kilns, all types of clinker)
% altern K-Up to Clinker
All alternative fuels types MJ (Low Heat Value) consumed (all kilns, all types of clinker) divided by Heat
Alternative fuels are non fossile fuels which replace the fossile fuels (coal, petcoke, oil, HVF, gas) in the cement
manufacturing process. They include: solvents, used oils, other hydrocarbons not fossile, tyres, solid schredded
wastes, impregnated saw dust, animal meal, other biomass, other solids, sewage sludge and other.
See attached file AF glossary.
Includes Fuels for Raw mix drying, clinker burning, fuel preparation and other consumption chargeable to clinker
Sum of indicators CR115X to CR125X
Sergiu Meauta
CR037X kWh/t
Power consumption /Tonnage : (by crusher, all products)
kWh/t crushed products by crushers 1- Quarry
All Kwh consumed in a workshop (by crushing system) from upstream storage to downstream storage divided by
the tonnage produced (by crushing system, all products).
On a dry basis.
Sergiu Meauta
CR040X kWh/t
Power consumption/Tonnage : (by raw mill , all types of raw mix)
kWh/t raw mill all raw mix 2-Raw mix preparation
All Kwhs consumed in a workshop (by raw mix mill, all types of raw mix) (from upstream storage to
downstream storage) divided by the tonnage produced (by raw mix mill, all types of raw mix).
On a dry basis.
Sergiu Meauta
CR044X kWh/t
Power consumption/Tonnage : (by kiln , all types of clinker)
kWh/t Kiln all KK 3-Burning
All Kwhs consumed in a workshop (by kiln, all types of clinker) (from upstream storage to downstream
storage) divided by the tonnage produced (by kiln, all types of clinker) .
Sergiu Meauta
CR048X kWh/t
Power consumption /Tonnage : (by finish mill , all types of cement)
kWh/t finish mill all Cem 4-Finish Grinding
All Kwhs consumed in a workshop (by finish mill, all types of cement) (from upstream storage to downstream
storage) divided by the tonnage produced (by finish mill, all types of cement).
Sergiu Meauta
CR050X kWh/t
Power consumption /Tonnage : (Finish grinding, all types of cement)
kWh/t all finish mills by Cem 4-Finish Grinding
All Kwhs consumed in a workshop (Finish grinding, all types of cement) (from upstream storage to
downstream storage) divided by the tonnage produced (Finish grinding, all types of cement).
Sergiu Meauta
CR051X kWh/t
Power consumption / T Solid fuels : (by coal mill , all types of solid fuel)
kWh / t all grinded solid fuels 6-Fuel preparation
All kWh consumed in a fuel preparation workshop (by coal mill, all types of solid fuel) (from upstream storage
to downstream storage) divided by the sum of produced tons of all types of solid fuel.
On a dry basis
Sergiu Meauta
CR054X kWh/t
Power consumption /Tonnage produced : (Up to clinker, all types of clinker)
kWh/t all KK K-Up to Clinker
All Kwhs that has been effectively consumed to produce one tonne of clinker, including the part of the quasi
process and general services allocated to clinker (all types of clinker).
Analyse trend of your plant

Jacques Denizeau
CR056X kWh/t
Power consumption /Tonnage produced :(Up to cement, all types of cement)
kWh/t all Cem C-Up to Cement
All Kwhs that has been effectively consumed to produce one tonne of cement, including the part of the quasi
process and general services allocated to cement (all types of cement).
Unit clinker power consumption (CR054X) divided by the additive coefficient (CR077X) plus unit grinding
power consumption (CR050X). Analyse trend of your plant
Jacques Denizeau
CR057X MWh
Power consumption : (by crusher , all products)
Kwh by Crusher all prdts 1 - Quarry
All Kwhs consumed (by crusher , all products).

Jacques Denizeau
CR060X MWh
Power consumption : (by raw mill , all products)
Kwh by Raw mill all prdts 2 – Raw mix preparation
All Kwhs consumed (by raw mill , all products).
Jacques Denizeau
CR064X MWh
Power consumption : (by kiln , all types of clinker)
Kwh Kiln all KK 3 - Burning
All Kwhs consumed (by kiln , all types of clinker).
Jacques Denizeau
CR068X MWh
Power consumption : (by Finish mill , all products)
Kwh by Finish mill all prdts 4 – Finish Grinding
All Kwhs consumed (by Finish mill , all products).

Jacques Denizeau
CR070X MWh
Power consumption : (Finish grinding, all products)
Kwh by Finish grinding all prdts 4 – Finish Grinding
All Kwhs consumed (Finish grinding, all products).

Jacques Denizeau
CR072X MWh
Power consumption : (Fuel preparation, all products)
Kwh Fuel prep all prdts 6 – Fuel Preparation
All Kwhs consumed (Fuel preparation, all products).

Jacques Denizeau
CR074X MWh
Power consumption : (Up to clinker, all types of clinker)
Kwh Up to KK all KK K – Up to clinker
All Kwhs consumed (Up to clinker, all types of clinker).
Including the part of the quasi process and general services allocated to clinker.
Jacques Denizeau
CR076X MWh
Power consumption : (Up to cement , all types of cement)
Kwh Up to Cem all Cem C-Up to Cement
All Kwhs consumed (Up to Cement in bin, all types of cement).

Including the part of the quasi process and general services allocated to cement.
Jacques Denizeau
CR077X n
C/K - Additive coefficient : (by product and/or all products)
C/K P-Plant
Cement/clinker ratio: Tonnage of Cement produced, divided by the tonnage of clinker of any origin consumed.
Slag and Cement Production Record
Objectives:
- Promote the approach that allows performance tracking in the plant
- Reconcile the two reporting types: Technical (CKHC/MMP) and Financial (Control)
General rules:
- Former "Cement in bin" will be understood as "Cement in bin before packing and shipping".
In this notion we will include mixing/blending operations. Blending operations are an extension of the grinding
operations. Blender/mixer is part of the Grinding Shop.
- Total Technical cost: indicator CE005X will include all the costs associated with the mixing/blending operations.
- Other indicators. Ex: total power consumption: indicator CR056X will include the power, if any, related to
mixing/blending. Same rule for other concerned position (ex: manpower)
Consequences on slag/cement production record:
• Slag ground with clinker in a cement plant enters in the C/K calculation. It represents the typical case. It
includes:
- Slag introduced in the cooler
- Slag introduced in the finish mills
NB: Please check on the ARM definition regarding the slag introduced in the kiln feed, kiln middle or at the kiln
end.
• Slag ground in a cement plant or in a grinding station and sold as pure slag (ex: Newcem) does not enter in the
calculation of the C/K neither at the site level nor at BU level. The ground slag is reported in CKHC production for
the respective finish mills.
• Slag ground in a cement plant or in a grinding station and blended with cement in the same plant but after silage
(ex: Maxcem) is included in the C/K ratio. The ground slag is reported in CKHC production for the respective
finish mills. The cost for blending is part of "Cement in bin before packing and shipping".
• Purchased ground slag blended with cement after silage but in the same plant is included in the C/K ratio. The
purchased slag cost is included in the "Cement in bin before packing and shipping" cost.
• Slag reground with cement in a regrinding station enters in the C/K calculation and in the "Cement in bin before
packing and shipping" costs (including at BU level).
Kiln dust reintroduced in cement is counted as an additive and not as clinker. Clinker produced in the site or
purchased by the site. Cement + cementitious material (excluded Special product, Lime)
Benchmark with all plants
Sergiu Meauta
CR096X %
Quantity consumed of clinker : (all types of clinker, all types of cement)
All KK Consum P - Plant
Tonnage of clinker (all types of clinker) consumed to produce cement (all types of cement) during the period.
Clinker produced in the site or purchased by the site.
Sergiu Meauta
KK001X LMU/t
Average Unit Technical Cost : (all types of clinker)
KKTotal K-Up to Clinker
Weighted average unit cost of all clinkers produced in a site during a given period.
Unit costs are computed according to Costing Methodology
KK020X + KK019X + KK014X + KK007X + KK003X + KK004X + KK005X + KK021X Benchmark with plants in
the same economic group - all plants with similar economy based on labor cost
Pierre Tonin
KK015X LMU/t
Maintenance expenses/t : (by type of clinker)
KK Maint K-Up to Clinker
Unitary Maintenance Cost (Cost lines 230, 240 and 250) for clinker (by type of clinker) during a given period.
These expenses include all expenses for maintenance chargeable to clinker manufacturing.
KK012X + KK013X + KK014X
Pierre Tonin
MA001X n
MCI - Maintenance cost index : (all types of cement)
Maint Cost Ind P-Plant
Ratio of Maintenance Actual cost to Maintenance Reference cost for a plant.
Only on a yearly basis.
CE016X divided by MA002X
Jean-Marc Albert
MA002X LMU/t
Maintenance Reference cost per ton
Ref P-Plant
The maintenance Reference cost per ton is determined for each site on the basis of : target reference cost, type
of process, ratio Raw mix/Clinker, ratio Cement/Clinker, technical particularities , plant capacity utilization, local
economic conditions.
The maintenance Reference cost per ton is the theoritical cost calculated for cement in bin (from Quarry to Finish
Grinding process steps including cement storage and excluding Packaging and Shipping Costs).
This Value is computed for each plant by DPC on yearly basis.
Technical particularities are calculated by plant and Technical Center then validated by DPC.
Jean-Marc Albert
MA074X %
Equipment Failure Rate Burning Line (by kiln, all products)
EFRB 3-Burning
For a given kiln, during a given period:
Sum of stoppage hours caused by Equipment failure * 100 divided by (Effective operating time + Sum of Hours of
shutdowns on incidents)
For this indicator the "upstream concept" applies
1 - EFRB and PFRB (Process failure rate burning line) are related to Burning
Line Reliability Factor as follows: RF (Kiln) = 100 - EFRB - PFRB

2 - EFRB measures the technological status of burning line through equipment incidents. It indicates if specific
maintenance actions are necessary to improve overall reliability and actions from the past have been successful.
3 - There are 4 main impacts:
· Loss of clinker production : especially for sold out plants this has an important economical impact
· Each stoppage (short or long) causes quality fluctuation
· Start up after a long stoppage has a significant cost
· During stoppage and start up phases equipment are stressed, suffered cumulative fatigue that could lead to
major failure.
t2(equipment) PA090X (equipment)
EFRB = ------------------- * 100 = ---------------------------- * 100

t1 + t2 PA088X + PA090X
t2(equipment): Equipment related incident stoppage duration: Each relevant incident which is caused by
mechanical, electrical, instrumentation and civil work problem.
Stoppage: An incident is counted as stoppage of the burning line if the kiln feed is stopped.
Kiln Line: According to Lafarge Codification, the kiln line includes all equipment of burning line i, code 3i.
The upstream concept requires that stoppages by equipment incidents of the raw mill, which result in a stoppage
of the burning line, have to be included.

Jean-Marc Albert
PA007X n
Number of Cement types
Nb Prod C-Up to Cement
Number of marketable types of Cement produced during the given period.
Cement + cementitious material (excluded Special product, Lime, Clinker)
Information only
Sergiu Meauta
PA012X t
Quantity produced : (by equipment, all types of Cement)
ProdCem by equip all Cem 4-Finish Grinding;C-Up to Cement
Tonnage produced of cement (by equipment, all types of cement) during a given period.
Not separable equipments (example : press plus ball mill) are accounted as a single equipment.
Sergiu Meauta
PA014X t
Quantity produced : (all equipments , by type of Cement)
ProdCem all equip by Cem 4-Finish Grinding;C-Up to Cement
Tonnage produced of cement (all equipments, by type of cement) during a given period.
Sergiu Meauta
PA015X t
Quantity produced (all types of Cement)
ProdCem all equip all Cem 4-Finish Grinding;C-Up to Cement
Tonnage produced of cement (all equipments, all types of cement) during a given period.
Cement + cementitious material (excluded Special product, Lime, Clinker)
Information only
Sergiu Meauta
PA018X %
Cement in bulk percentage : (all types of cement)
PurchCem all Cem 5 – Packing and shipping
Tonnage produced of cement in Bulk (all types of Cement) divided by tonnage produced of Cement (all types of
Cement) in bulk and bagged during a given period.
Sergiu Meauta
PA019X t
Quantity produced : (by kiln, all types of Clinker)
ProdKK by equip all KK 3-Burning;K-Up to Clinker
Tonnage produced of clinker (by kiln, all types of clinker) (at cooler(s) outlets) during a given period. (Upstream
dust, especially dust from grate exchangers when reintroduced is counted as an additive).
Sergiu Meauta
PA021X t
Quantity produced (all types of Clinker)
ProdKK all equip all KK 3-Burning;K-Up to Clinker
Tonnage produced of clinker (all kilns, all types of clinker ) (at cooler(s) outlets) during a given period.
(Upstream dust, especially dust from grate exchangers when reintroduced is counted as an additive).
Information only
Sergiu Meauta
PA022X t
Quantity produced : (all kilns, by type of Clinker)
ProdKK all equip all KK 3-Burning;K-Up to Clinker

Tonnage produced of clinker (all kilns, by type of clinker ) (at cooler(s) outlets) during a given period.
(Upstream dust, especially dust from grate exchangers when reintroduced is counted as an additive).
Sergiu Meauta
PA023X t
Quantity received : (all types of clinker)
RecievedKK all KK 4-Finish Grinding
Tonnage received of clinker (all types of clinker) during a given period. For example : Clinker acquired outside
the site.
Sergiu Meauta
PA026X t
Quantity produced : (by raw mill, all types of raw mix)
ProdRM by equip all RM 2-Raw mix preparation
Tonnage produced of raw mix (by raw mill, all types of raw mix) during a given period.
On a dry basis. Not separable equipments (example : press plus ball mill) are accounted as a single
equipment.
Sergiu Meauta
PA028X t
Quantity produced : (all types of Crushed products)
ProdQC by equip all pdts 1 - Quarry
Tonnage produced of Crushed products(all types) (Ending quarry) during a given period (e.g. prehomo outlet).
On a dry basis. Not separable equipments (example : press plus ball mill) are accounted as a single
equipment.
Sergiu Meauta
PA035X t
Quantity shipped : (all types of clinker)
KK ship 5-Packing and Shipping
Tonnage shipped of clinker (all types of clinker) during a given period.
Sergiu Meauta
PA040X t
Quantity shipped : (all types of cement, all types of shipments)
Cem shipped 5-Packing and Shipping
Tonnage shipped of cement (all types of cement, all types of shipments) during
a given period.
Sergiu Meauta
PA042X t
Quantity shipped : (all types of cement in bags)
Cem bags shipped 5-Packing and Shipping
Tonnage shipped of cement in bags (all types of cement) (including big bags) during the given period.
Sergiu Meauta
PA044X t
Quantity shipped : (all types of cement in bulk)
Cem bulk shipped 5-Packing and Shipping
Tonnage shipped in bulk (all types of cement) during a given period.
Sergiu Meauta
PA045X %
Cement in bags shipped percentage : (all types of cement)
% Cem bags shipped 5-Packing and Shipping
Tonnage shipped of Cement in bags (all types of cement) (including Big Bags) divided by total tonnage of
Cement shipped (all types of cement) during a given period.
Sergiu Meauta
PA087X h
T- Available Opening hours
All the hour of the given period except for Quarry and shipping :(local conditions) number of hours : month (31
days) 31X24 = 744 hours. Monthly duration could be 745 when daylight saving time is added (or removed). Year
(365 days) 365X24 = 8760 hours.
T = t1 + t2 + t3 + t4 + t5
Sergiu Meauta
PA088X h
t1 - Effective Operating time : (for kilns only, by product)
t1- kiln
Hours of operation for kilns during a given period: hours of kiln feeding (by product).
Sergiu Meauta
PA089X h
t1 - Effective Operating time : (by equipment except kilns)
t1-equip
Hours of operation for an equipment during a given period: hours of rotation of the main motor (by product).
Sergiu Meauta
PA091X h
t2 - CHSI - Cumulated Hours of Shutdowns on Incidents : (by equipment)
CHSI
Cumulated Hours of shutdowns on incidents for a given equipment during the given period = Opening hours
minus Effective Operating time minus Scheduled downtime minus Circumstance downtime (all products).
Defined as unschedulded stoppages due to electrical, mechanical, production, process,etc.Events on which the
site can impact.
Jacques Denizeau
PA091X h
t4 - Circumstance downtime
Circumstantial
Stoppages due to external factors such as strikes, market (full inventories), etc. Events on which the site has no
or limited control (all products).

Stoppages due to external factors such as strikes, market (full inventories), etc. Events on which the site has no
or limited control (all products).
Downtime hours resulting from climatic conditions (rainfalls, wind, cold temperature…) should normally be
recorded as Incident Stoppage Hours. For exceptional cases of freezing, flooding conditions, etc., the decision as
to whether the downtime is an incident or a circumstance would have to be determined on a case by case basis.
IMPACT OF AN INCIDENT FROM ONE SYSTEM TO ANOTHER: Hot clinker from the kiln has be diverted to the
hot bin via an equipment which is part of the mill system. Therefore, the mill has to be stopped to allow the
operation fo such equipment a necessary. The mill was able to run, but the shift foreman decided to divert the
production to keep the kiln in operation. Mill downtime is counted as Circumstance Stoppage.
POWER DOWNTIME 1) Power contract - If the power contract is such that a piece of equipment has to be down
for a certain
no work period of on
is performed time during
the the day
equipment or during
(yard, the year, .there
maintenance. are
. ), the two possibilities
downtime in case of Stoppages:
is a Circumstance type. b) the a)
stoppage is used to perform some work, then it becomes Scheduled or Incident downtime depending on the
degree of Scheduling. Most of the time it should be considered as Scheduled. 2) Electrical equipment belonging
to the Power Company If a power stoppage happens on an equipment which belongs to the Power Company, the
downtime should be considered as a Circumstance. Ex: Power Company’s sub-station tripped out due to storm.
(Plant has no control of this). 3) Electrical equipment belonging to the plant A power stoppage occurs on a piece
of equipment which belongs to the plant. It is an Incident stoppage. If, however, the failure is due to an “Act of
God”, over which the plant has no control, or is not expected to have protection from, it is a Circumstance. Note:
Each plant must develop a list of circumstances which would apply here. 4) Plant generates its own electricity
When the incident on the power generator causes the shutdown of another equipment, this downtime is
Circumstance Stoppage. The plant could have avoided the situation by purchasing electricity for production.
However in the case of an incident on a piece of equipment due to a switch from plant power station to the local
electricity distributor, the event would be considered as an Incident stoppage.
Circumstance stoppage hours can be either scheduled or not. Examples: - Scheduled situation: At budget time,
sales are forecasted to be low, allowing the kiln to be kept down for an extended period of time. Budgeted
scheduled downtime should cover the time required to perform the work under normal conditions. If conditions
allow to stretch the duration of downtime by using less overtime, etc., then the additional time is considered as
Circumstance stoppage hours. - Unscheduled situation: The power company is on strike. - Scheduled or
unscheduled situation: When the homo silo is full, the raw mill downtime is considered Circumstance.
Jacques Denizeau
PA096X h
MTBF - Mean Time Between Failure : (by equipment)
MTBF 1-Quarry;2-Raw mix preparation;3-Burning;4-Finish Grinding

Effective operating time divided by the total number of shutdowns for incidents.
If there is no shutdown for incident MTBF is equal to effective operating time.
For a kiln, PA096X = PA088X / PA098X For another equipment PA096X = PA089X / PA098X
Jean-Marc Albert
PA098X n
NSFI- Incident stoppages : (by Equipment)
NSFI 1-Quarry;2-Raw mix preparation;3-Burning;4-Finish Grinding
Total number of stoppages for incident during the given period, whatever each stoppage duration.
Jacques Denizeau
PA104X n
NSFI- Incident stoppages : (All kilns)
NSFI 3-Burning
Aggregate of the 'NSFI' of each kiln (PA098X)
In case of several burning lines, NSFI = Maximum (NSFIx for UFx >= 60%) if no line has an Utilization
Factor >= 60% then NSFI = NSFI of the line with the highest UF. In case of one burning line, this is the NSFI
of this line.
Jacques Denizeau
PA111X t
Quantity produced : (by equipment,all types of Fuel prepared)
ProdFuelprep by equip all pdts 6-Fuel preparation
Tonnage produced of Fuel prepared (by equipment, all types of fuel prepared) during a given period.
Sergiu Meauta
PA133X t
Potential Production
Pot prod 3-Burning
Tonnage of clinker (all kilns, all type of clinker) during a given period that could be produced with a perfect
Reliability Factor.
It is defined as the ratio between the actual clinker production divided by the actual reliability factor.
Note: On monthly level, in the possible case that the kiln reliability factor (PR039X) is zero then the Potential
Production is calculated: PR050X * PA091X * 0.97
Site level: PA021X / PR038X
Kiln level: PA019X / PR039X
Sergiu Meauta
PA121X h
MTBF - Mean Time Between Failure : (all kilns)
MTBF 3-Burning
Aggregate of the 'MTBF' of each kiln (PA096X) according to the above formula
In case of several burning lines, MTBF = Minimum (MTBFx for UFx>=60%) if no line has an Utilisation
Factor >=60%, then MTBF = MTBF of the line with the highest UF. In case of one burning line, this is the
MTBF of this line.
Jean-Marc Albert
PE002X n
Site headcount : (Internal population) (Average)
Total Internal Pop P-Plant
Average of site population (including shipping), for all categories of personnel.
but excluding manpower under outside contracts. Includes Site general services, but does not include
services usually located in a regional or head office. Plants hosting head or regional office staff must
exclude them in the calculation.

PE005X+PE004X+PE006X
Jim Black
PE003X n
Manufacturing population : (Average)
Mfg. pop. P-Plant
Average of population for cement in bin manufacturing (all types of cement), for all categories of personnel.
excluding shipping personnel as well as the equivalent population for the maintenance of shipping and
manpower under outside contracts.
PE005X+PE004X Benchmark with all plants
Jim Black
PE021X h
Hours worked Cement Division activity : (Lafarge employees)
P-Plant
Total worked hours on company authorised activites in the Cement Division activity. Includes overtime hours
paid, normal working hours on the job, balance of banked overtime hours to be recuperated, shower,
changing room time, professional training and coffee break and other. Excludes Personnel representation, paid
vacation, days off, bank holidays, Maternity leave, sick leave.
Cement Division Activity includes Building Materials Activity and Non Building Materials Activity. Lafarge
employees : any person directly employed by a Lafarge company, including casuals (people employed from
the street directly by site irregularly, on daily or weekly basis, agency staff, temporary employees, trainees,
seamen & drivers.
Jim Black
PE023X h
Hours worked Clinker : (all types of clinker)
h KK P-Plant
Hours worked, overtime included, during a given period for clinker manufacturing, in Production, Maintenance
and part of the hours of General Services, for all categories of personnel, but excluding manpower under
outside contracts.
Jim Black
PE024X h
Hours worked : (Finish Grinding, all types of cement)
Hours worked cement P-Plant
Hours worked, overtime included, during a given period at the Finish grinding Process step in Production,
Maintenance and part of the hours of General Services, for all categories of personnel, but excluding manpower
under outside contracts.
Jim Black
PE029X h/t
Manpower productivity
h/t Cem P-Plant
Total hours worked Cement divided by the quantity produced of cement (all types of cement) during a given
period.
Expressed in h/t calculated using the ratio method for cement in bin.
PE022X divided by PA015X Analyse trend of your plant
Jim Black
PE031X h
Overtime hours
Overtime P-Plant
Number of hours in excess of the theoretical hours.The theoretical hours are the translation of the hours on
contract for a given period (a day, a week, a calendar month, etc.). For example, the theoretical hours of each
month for an individual depend on the actual number of days of the month, the number of week-ends, the shift
organization, etc...
Jim Black
PE033X h
Payed hours
Payed P-Plant
Paid hours are the hours on contract plus overtime (at one's post or not) minus non-paid absence.
Hours on contract are the monthly hours used as a basis for the employement contract. For example, in France
169,58 hours are the regular monthly hours on contract which correspond to the legal 39 hours a week, 84,79
hours are the corresponding hours on contract for a half time employee, etc..
Jim Black
PE036X %
Overtime
% OT P-Plant
Total overtime hours divided by total normal hours multiplied by 100 For all categories of personnel including
staff and management.
Jim Black
PE052X h
Hours worked : (Packing & shipping, all types of cement)
Hours worked P&S P-Plant
Hours worked, overtime included, during a given period at the Packing and Shipping Process step in Production,
Maintenance and part of the hours of General Services, for all categories of personnel, but excluding manpower
under outside contracts.
PE021X - PE022X - PE023X
Jim Black
PR002X n
KFUI - Kiln feed uniformity index : (by kiln, by main type of clinker)
KFUI(C3S) 3-Burning
Calculated on C3S by: Sum [(Ii-Ic)(Ii-Ic)] / number of measurements; (by kiln, by type of clinker).
On all samples taken during a given period (month or year). li = C3S measured on daily grab sample (mix of
3 samples taken within 5 minutes) at kiln feed, for the raw mix corresponding to the clinker. Ic = C3S target
(set point). This indicator is calculated only for the main type of clinker.
Jacques Denizeau
PR003X
KFUI - Kiln feed uniformity index : (all kilns, by main type of clinker)
n
KFUI(C3S) 3-Burning
Average of [PR002X] "Kiln feed uniformity index, KFUI (by kiln, by main type of clinker)" weighted by
[PA020X] "Quantity produced (by kiln, by main type of clinker)".
Jacques Denizeau
PR004X n
UI(SO3) - Clinker uniformity index : (by kiln, by main type of clinker)
U SO3 3-Burning
UI(SO3) = 100 x sigma (SO3 KK) / (1 + average (SO3 KK)
On all samples taken during a given period (month or year). Sometimes called KSUI.
Jacques Denizeau
PR005X n
UI(SO3) - Clinker uniformity index : (all kilns, by main type of clinker)
UI(SO3) 3-Burning
Average of [PR004X] "Clinker Uniformity UI(SO3) (by kiln, by main type of clinker)" weighted by [PA020X]
"Quantity produced (by kiln, by main type of clinker)".
Jacques Denizeau
PR009X %
s'(FCaO) - Clinker Free Lime standard deviation : (all kilns, by main type of clinker).
U f CaO KK 3-Burning
Average of [PR008X] "Clinker Free Lime standard deviation (by kiln, by main type of linker)" weighted by
Jacques Denizeau
PR010X %
FCaO - Free lime Uniformity Index : (by kiln, by main type of clinker).
Free Lime 3-Burning
s'(Free Lime) divided by (0,2 * Mean (Free Lime) +0,1) during a given period.
The free lime uniformity index is the main indicator to characterise the stability of the burning conditions.
We assume, that under very stable burning conditions the SD of the free lime is not more than 20% of the
absolute value (Coefficient of Variation < 20 %) - in this case a kiln is class A. The term "+0.1" in the
calculation stands for the accuracy of the free lime analysis. Otherwise we would calculate completely
meaningless values for very low absolute free lime figures. Of course this figure is more meaningfull, if the
free-lime is a good measure of the burning conditions (what is not the case for some of our kilns - mainly
some of our long kilns). Therefore, this indicator has to be seen in connection with the absolute amount of
the free lime.
Jacques Denizeau
PR011X %
FCaO - Free Lime Uniformity Index : (all kilns, by main type of clinker).
FLUI 3-Burning
Average of [PR010X] "Free Lime Uniformity Index, FLUI (by kiln, by main type of clinker)" weighted by
Jacques Denizeau
PR013X %
m(FCaO) - Clinker Free Lime average : (all kilns, by main type of clinker).
% f CaO KK 3-Burning
Average of [PR012X] "Clinker Free Lime average (by kiln, by main type of clinker)" weighted by [PA020X]
"Quantity produced (by kiln, by main type of clinker)".
Jacques Denizeau
PR015X %
Utilization factor : (by Crusher)
Utilisation factor by crusher 1 - Quarry
For a given equipment, Effective Operating time divided by available opening hours.
Not separable equipments (example : press plus ball mill) are accounted as a single equipment. Generally
calculated with the LUCIE Expert system.
Sergiu Meauta
PR017X %
Utilization factor : (by Raw mill)
Raw Mill UF 2-Raw mix preparation
For a given raw mill, Effective Operating time divided by available opening hours.
Jacques Denizeau
PR019X %
Utilization factor : (by Solid fuel mill)
Fuel Mill UF 6-Fuel preparation
For a given solid fuel mill, Effective Operating time divided by available opening hours.
Jacques Denizeau
PR021X %
Utilization factor : (by Kiln)
Kiln UF 3-Burning
For a given Kiln, Effective Operating time divided by available opening hours.
Sergiu Meauta
PR023X %
Utilization factor : (by Finish mill)
Finish Mill UF 4-Finish Grinding
For a given Finish mill, Effective Operating time divided by available opening hours.
Jacques Denizeau
PR028X %
Operating time in automatic OTA : (by equipment)
% auto by equip 2-Raw mix preparation;3-Burning;4-Finish Grinding;6-Fuel preparation
The Effective operating time on automatic control (Lucie) during a given period divided by the Effective
operating time during the same period multiplied by 100 (by equipment).
Only applicable to equipment automated by the Lucie automation software. For the CKHC report equipment
having an OTA lower than 15 % is considered as not automated, the value will not be taken in consideration.
Jacques Denizeau
PR030X h
Automation Confidence Month :(by kiln)
Conf Kilns 3-Burning
For a given month, the longest continuous operation of the kiln on automatic without manual intervention.
The value is not calculated If a kiln operates less than 10 days during a given month.
Jacques Denizeau
PR033X %
Reliability factor : (by crusher)
Reliability factor by crusher 1 - Quarry
Effective operating time divided by ("Effective operating time" + "Production stoppages on incidents") during a
given period.
For a given period, if there is no schedulded and no circumstance hours :Reliability factor = Utilization factor.
Jacques Denizeau
PR035X %
Reliability factor : (by Raw mill)
Raw mill RF 2-Raw mix preparation
For a given Raw mill, "Effective operating time" divided by ("Effective operating time" + "Production stoppages
on incidents") during a given period.
Jacques Denizeau
PR037X
Reliability factor : (by Solid fuel mill)
%
Solid fuel mill RF 6-Fuel preparation
For a given Solid fuel mill, "Effective operating time (in hours)" divided by ("Effective operating time (in hours)" +
"hours of "Stoppages on incidents ") during a given period.
Jacques Denizeau
PR038X %
Reliability factor : (all Kilns)
Kilns RF 3-Burning
Average, weighted by the "potential production", of the reliability factor of each kiln (PR039X).
Jacques Denizeau
PR039X %
Reliability factor : (by Kiln)
Kiln RF 3-Burning
For a given Kiln, "Effective operating time" divided by ("Effective operating time" + "Production stoppages
hours on incidents") during a given period.
For a given period, if there is no schedulded and no circumstance hours :Reliability factor = Utilization
factor. For a Kiln, a stoppage is schedulded during preparation of the budget. If the schedulded stoppage is
moved up more than 15 days, the first 5 days are considered as incidents. If stoppage is lengthened for
technical reasons, the excess duration is considered as an incident. No more than two scheduled
shutdowns can be planned per year. an incident on the raw mill which result in a stoppage of the kiln line is
included in the RF burning line calculation.
Jacques Denizeau
PR041X %
Reliability factor : (by Finish mill)
Finish mill RF 4-Finish Grinding
For a given Finish

on incidents") mill,
during "Effective
a given operating time" divided by ("Effective operating time" + "Production stoppages
period.
For a given period, if there is no schedulded and no circumstance hours :Reliability factor = Utilization
factor.
Jacques Denizeau
PR048X %
Performance factor : (by Kiln)
PF Kiln 3-Burning
Output (by kiln) of clinker the most produced during a given period divided by the "Rated Capacity" of the kiln.
The Reference Performance factor value is provided by the DPC: PR054X divided by PR050X
Jacques Denizeau
PR050X t/24h
Rated Capacity : (by Kiln)
Rated kiln 3-Burning
Best historical Production (recorded on the main product type) during 7 consecutive days divided by 7, In
case of major and permanent modification in operating conditions, the rated capacity may be reduced from the
previous year value. Requests for decreasing the rated capacity must follow a specific procedure and revised
value must be approved by DPC.
Supplier's guarantee during start-up. A new production record set during a year will not come into effect until
the following year.
Jacques Denizeau
PR053X t/24h
Output : (by Kiln, all types of Clinker)
All KK output 24 by kiln 3-Burning
Quantity produced of all types of Clinker (t of clinker cooler exit) divided by the "Effective operating time"
(hours of Kiln feeding) to produce all types of clinker for a given period multiplied by 24.
Jacques Denizeau
PR057X t/h
Output : (by Finish mill, all types of product)
Finish mill Output 4-Finish Grinding
Quantity produced of all types of product divided by Effective operating hours to produce all types of product
for a given period.
Jacques Denizeau
PR061X t/h
Output : (by Solid fuel mill, all types of Solid fuel)
All Solid fuels output 6-Fuel preparation
Quantity produced on a dry basis of all types of Solid fuel divided by the total operating hours for a given
period.
Jacques Denizeau
PR063X t/h
Output : (by Raw mill, all types of Raw mix)
Outp Raw 2-Raw mix preparation
Quantity produced on a dry basis of all types of Raw mix divided by the total operating hours for a given
period.
PA026X(all types of raw mix) divided by PA089X(by equipment).
Jacques Denizeau
PR069X FU
Fineness : (by mill system, by product)
2-Raw mix preparation;4-Finish Grinding
Average on the given period of Fineness measurment. (Specify the Fineness unit).
It should be: - for cement: Specific Surface Blaine in m2/kg - for raw mix: retained on screen of 90 µm or
100 µm (or equivalent in mesh (ASTM series)).
Jacques Denizeau
PR073X t/h
Output : (Crushing, all types of crushed products)
Crush output 1-Quarry
Sum of Output (By crusher, all types of Crushed products) for a given period.
Sergiu Meauta
PR074X h
Automation Confidence Month : (by raw mill)
Confidence raw mill 2 – Raw mix preparation
For a given month, the longest continuous operation of the raw mill on automatic without manual intervention.
The value is not calculated If the raw mill operates less than 10 days during a given month.
Jacques Denizeau
PR102X %
Process Failure Rate Burning Line (by kiln, all products)
PFRB 3-Burning
For a given kiln during a given period:

Sum of stoppage hours caused by Process failure * 100 divided by (Effective operating time + Sum of Hours of
shutdowns on incidents)
For this indicator the "upstream concept" applies
The burning line reliability is linked with the PFRB and the EFRB (Equipment failure rate Burning Line) as follows:
RF(kiln) = 100 - PFRB - EFRB
Explanation: A poorly mastered process very often causes stoppages of the kiln line. This indicator allows
measurement of the influence of the process on the overall reliability of a kiln line and is a basis for corrective
actions. Over time it also shows the success of previous corrective actions.
There are three main economic impacts for this indicator:
1) Loss of clinker production has an important economic impact especially for sold out plants
2) Each stoppage reduces the refractory life, stresses all mechanical equipment and increases heat consumption
because of heating up the system.
Even if these influences are not so easy to measure, they have an important economic impact.
3) Each stoppage causes quality fluctuations
t2 (process) PA090X (process)
PFRB = ------------------ * 100 = ---------------------------- * 100
t1 + t2 PA088X + PA090X
t2 (process) : Process related incident: Each relevant incident which is caused by a not fully mastered process.
Kiln line: According to Lafarge Codification, the Kiln Line includes all equipment of burning line i, Code 3i.
The upstream concept requires that stoppages by process incidents of the raw mill, which result in a stoppage of
the kiln line, have to be included.
Jacques Denizeau
PR103X h
Automation Confidence Month : (by Coal mill)
Conf. coal mill 6-Fuel Preparation
For a given month, the longest continuous operation of the coal mill on automatic without manual intervention.
The value is not calculated If a coal mill operates less than 10 days during a given month.
Jacques Denizeau
PR105X h
Operating hours in Automatic : (by equipment)
Auto P - Plant
Operating hours in automatic (by equipment)
Jacques Denizeau
QU004X MPa
28 day strength: (by type of cement)
28d str C – Up to cement
Cement strength on mortar after 28 days determined following the local Standards (by type of cement).
Grab sample taken at least once or twice per week depending on requirements of local standards. Grab sample
to be taken from shipping load point, except if another method is proved to give the same result, and consist of
either one whole product bag, or a composite of 3 grab samples over a 5 minute period.
Total sample weight to be more than 3 kg.
Yves Guitton-Fumet
QU009X MPa
28 day strength uniformity (by type of cement)
28d SU C – Up to cement
Standard deviation is calculated on the value of all 28 day strengths (by type of cement) corresponding to the 12
months considered.
If the strength target changes during the year (agreed by management only), then a new data population must be
started. Weight each data population, if applicable, by the number of samples within the 12 month period.
Yves Guitton-Fumet
QU014X MPa
28-day strength Uniformity "main types of cements"
P-Plant
28 day strength uniformity of main products calculated as the Standard Deviation of mortar strengths for 12
months for the "main types of Cements".
Grab sample taken at least once or twice per week depending on local standard requirements. Grab
sample to be taken from shipping loading point, except if another method is proved to give the same result,
and consists of either one whole bag, or a composite of three(3) grab samples over a five(5) minute period.
Total sample weight to be more than 3kg. If the strength target changes during the year (agreed by
management only), then a new data population must be started. Weight each data population, if applicable,
by the number of samples within the 12 month period. Note: the former exclusion and/or limitation of
blended products is removed from the definition. Main types of cements are defined as the largest cement
shipment then the second largest cement shipment and so on until at least 50% of the total cement
shipment, during the 12 month period, is considered.
Yves Guitton-Fumet
QU026X %
IQP (product quality indicator)
IQP P-Plant
The IQP measures the percentage of time results for up to 5 quality parameters selected for each product
produced by the plant, are at or within set upper and/or lower limit(s).
The IQP (Indicateur Qualité Produit or Product Quality Indicator) is an indicator of product quality, as agreed
between marketing & sales and manufacturing staff, based on customer requirements for all product(s) produced
at a plant.
The indicator measures the percentage of time results for up to 5 quality parameters selected for each product
produced by the plant, are at or within set upper and/ or lower limit(s).
Parameters selected should reflect the performance characteristics desired by the main customers using each
product e.g. cement physical, chemical or paste, mortar, micro-concrete or concrete test results. The upper and/or
lower limit(s) for all parameters of each product are jointly set by manufacturing & marketing personnel based on
market requirements and plant capabilities. The limit(s) are set, such that an IQP of 100 should result in zero
customer complaints attributed to cement quality.
For reporting purposes, the IQP will be a single number calculated for each plant based on results obtained
during a calendar year.
A plant can be a cement plant, or a grinding facility (cement or slag)
Yves Guitton-Fumet
4.0 Definitions
4.1 Incident Category
4.1.1 Fatal Injury (FI) – is a work-related injury that results in a loss of life, with no time limit between
the date of the incident and the date of the death. Excluded in all cases are all fatalities in transport to
and from home and work, criminal acts, and natural causes.
FI Example 1 – Two
representative’s sales
vehicle representative
is struck are driving
by a second vehiclea that
vehicle
ran to
a visit
stop asign.
customer
Both for a work
sales meeting. The
representatives diesales
from
complications related to the accident. This counts as two fatal injuries.
FI Example 2 – an electrical contractor sustains severe burns to his body while working in the plant. Two months
later the electrician dies as a result of a systemic infection related to the burn. This counts as one fatal injury.
4.1.2 Lost Time Injury (LTI) – is a work-related injury causing absence from one or more scheduled
workdays (or scheduled shifts), counting from the day after the injury occurs to the day before the
individual returns to normal or modified work.
LTI Example 1 – an office administrative assistant falls and sustains a fracture to her arm on Monday. The medical
clinic immobilizes her arm with a cast and instructs the administrative assistant to stay home until Wednesday and will
be required to wear the arm cast for six weeks. The employee misses one day of work and has limited use of her arm
for six weeks.
LTI Example 2 – a QC technician falls off a ladder while collecting a sample and strains his shoulder. The technician
returns
shouldertorequires
work thesurgery
next day on modified
to repair duty (i.e.
the injury. The atechnician
medical injury). Twotomonths
is required later,from
be absent the work
doctorfordetermines
two weeksthe
to
properly recover from surgery (i.e. this injury is reclassified from a medical injury to a LTI with 14 lost work days).
LTI Example 3 – an auditor is traveling from the office to the plant for a meeting. His vehicle is struck by an oncoming
truck. He sustains a fractured wrist and is required to miss two weeks from work (i.e. this injury is a LTI with 14 lost
work days).
4.1.3 Medical Injury (MI) – is a non-lost time work-related injury that requires treatment by a trained
health care professional (nurse, doctor, physiotherapist, etc). Treatment does not include first aid (as
defined in 4.1.4) even if it is provided by a trained health care professional.
4.1.4 First Aid Injury (FA) – is a non-lost time work-related injury that requires one-time treatment of
minor scratches, cuts, burns, splinters and so forth, but does not ordinarily require medical care by a
trained health care professional. Such treatment and observation are considered first-aid even though
provided⇒by a trained health

Administration careimmunizations
of tetanus professional. First aid includes:
⇒ Cleaning, flushing, or soaking wounds on the skin surface
⇒ Use of wound coverings, e.g., gauze pads, BandAids™, or SteriStrips™
⇒ Use of hot or cold therapy
⇒ Use of eye patches
⇒ Use of any non-rigid means of support, e.g., wraps

⇒ Drinking of fluids to relieve heat stress
⇒ Use of t emporary immobilization devices while transporting an accident victim
, e.g., splints, neck collars, or backboards
⇒ Use of X-Rays
⇒ Drilling of fingernails or toenails to relieve pressure, or draining fluids from blisters
⇒ Use of simple irrigation or cotton swab to remove foreign bodies not embedded in or adhered
to the eye
⇒ Use of irrigation, tweezers, cotton swabs, or other simple means to remove splinters or foreign material from
areas other than the eye
⇒ Use of finger guards
⇒
⇒ Use of massages
Use of non-prescription medications at non-prescription strength
.
4.1.5 Near-Miss Incident (NM) – is a work-related incident that did not result in an injury but could
have resulted in an injury under different circumstances.
NM Example 1 – a crane operator raises the crane boom and it almost contacts an energized power line.
NM Example 2 – a work crew is preparing to enter a newly excavated trench to perform work. The trench wall
collapses before crew enters the trench.
4.1.6 Total Lafarge Employee Hours Worked – refers to actual hours worked (refer to 4.2.1).
4.1.7 Lost Work Days (LWD) – refers to calendar days.
LWD Example 1 – an equipment operator is injured on a Friday. The doctor instructs the operator not return to his job
until the following Tuesday. Because the operator was absent from his next scheduled workday (i.e. Monday), the
injury is classified as a LTI with 3 lost work days (i.e. calendar days: Saturday, Sunday, and Monday).
LWD Example 2 – an engineer sustains a LTI from a knee injury that initially results in 7 LWD's in December.
Subsequently, the doctor instructs the engineer to receive surgery to repair torn ligaments on January 10. The doctor
gives permission for the engineer to return to her job on January 25. This injury is classified as an LTI with 7 LWD's
reported in December and 14 LWD's reported in January.
4.2 Affected-Individual Classification

4.2.1 Lafarge Employee – any individual that is directly employed (i.e. temporary or permanent) by
Lafarge on a part-time or full-time basis or is managed by Lafarge whether or not the individual
receives remuneration directly from the Lafarge payroll system.
4.2.2 Contractor – any individual that is employed (i.e. short-term or long-term) by a contract
company or sub-contractor to perform work activities or services (including transport) for Lafarge.
4.2.3 Third-Party – any individual including vendors, suppliers, visitors, customers or others
interacting with Lafarge (e.g. a Lafarge vehicle collides with a 3rd party automobile).
4.3 Key Performance Indicators

4.3.1 Fatal Injuries (FI) – the total number of FI’s:
rd
FI = Total Number of FI’s by Lafarge Employee, Contractor, 3 Party categorized as Industrial and Road.
4.3.2 Lost Time Injuries (LTI) – the total number of LTI’s:
LTI = Total number of LTI’s in two distinct categories: i) Lafarge Employees, and ii) Contractors.
4.3.3 Lost Time Injury Frequency Rate (LTIFR) – the number of LTI’s + FI’s per million hours
worked:
LTIFR = (Total Lafarge Employee LTI’s+FI’s) (1.000.000) / (Total Lafarge Employee Hours Worked)
1
4.3.4 Severity Rate (SR) – the number of lost work days per one thousand hours worked:
SR = (Total Lafarge Employee LWD’s) (1.000) / (Total Lafarge Employee Hours Worked)
2
4.3.5 Medical Injury Frequency Rate (MIFR) = the number of MI’s per million hours worked:
MIFR = (Total Lafarge Employee MI’s) (1.000.000) / (Total Lafarge Employee Hours Worked)
Notes:
1
For Lafarge employee fatal injuries, 365 lost work days will be used for calculating the SR.
2
MIFR does not include lost time injuries.
4.3.6 Total Injury Frequency Rate (TIFR) = the number of FI’s, MI’s and LTI’s per million hours worked:

Cement KPIs - 2009

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Cement KPIs - 2009

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8/17/2019 Cement plant Key performance Indicators

NB: This Glossary presents the indicators specific to MMP.

Copyright 2007-2009 Lafarge SA – DPC/ Confidential 1/32

PRODUCTION COST ( cement costing)

Power consumption : (Up to clinker, all types of clinker) Mwh CR074X

Copyright 2007-2009 Lafarge SA – DPC/ Confidential 2/32

PRODUCTION COST ( clinker costing)

UI(SO3) - Clinker uniformity index: (all kilns, by main type of n PR005X

Reliability factor: (by Solid fuel mill) % PR037X

Output : (Crushing, all types of crushed products) t/h PR073X

Copyright 2007-2009 Lafarge SA – DPC/ Confidential 4/32

INPUT file (Actual and Budget)

Petcoke (like coal)quality

REPORT file (Actual and Budget)

5) PRODUCTION AND PROCESS section

Copyright 2007-2009 Lafarge SA – DPC/ Confidential 5/32

All expenses (60xxxx to 69xxxx) incurred in Finish grinding (CC 4xx).

ref :Chart of accounts Tree Structure.

Expenses of heat consumed all types of fuel during a given period.

All expenses (60xxxx to 69xxxx) incurred up to Clinker.

ref :Chart of accounts Tree Structure.

Copyright 2007-2009 Lafarge SA – DPC/ Confidential 6/32

Copyright 2007-2009 Lafarge SA – DPC/ Confidential 7/32

CE007X + CE008X Benchmarked across the entire Cement Division

Copyright 2007-2009 Lafarge SA – DPC/ Confidential 8/32

Does not include heat recovery.

Total heat Consumption (Low Heat Value) during a given period .

Does not include heat recovery.

Fuel preparation excluded

Copyright 2007-2009 Lafarge SA – DPC/ Confidential 9/32

Pitch, bottom products.

Copyright 2007-2009 Lafarge SA – DPC/ Confidential 10/32

Copyright 2007-2009 Lafarge SA – DPC/ Confidential 11/32

Analyse trend of your plant

All Kwhs consumed (by crusher , all products).

Copyright 2007-2009 Lafarge SA – DPC/ Confidential 12/32

All Kwhs consumed (by Finish mill , all products).

All Kwhs consumed (Finish grinding, all products).

All Kwhs consumed (Fuel preparation, all products).

All Kwhs consumed (Up to clinker, all types of clinker).

Copyright 2007-2009 Lafarge SA – DPC/ Confidential 13/32

All Kwhs consumed (Up to Cement in bin, all types of cement).

Copyright 2007-2009 Lafarge SA – DPC/ Confidential 14/32

Copyright 2007-2009 Lafarge SA – DPC/ Confidential 15/32

This Value is computed for each plant by DPC on yearly basis.

For a given kiln, during a given period:

For this indicator the "upstream concept" applies

Line Reliability Factor as follows: RF (Kiln) = 100 - EFRB - PFRB

3 - There are 4 main impacts:

· Each stoppage (short or long) causes quality fluctuation

· Start up after a long stoppage has a significant cost

EFRB = ------------------- * 100 = ---------------------------- * 100

of the burning line, have to be included.

ProdKK all equip all KK 3-Burning;K-Up to Clinker

Copyright 2007-2009 Lafarge SA – DPC/ Confidential 18/32

Tonnage shipped in bulk (all types of cement) during a given period.

Copyright 2007-2009 Lafarge SA – DPC/ Confidential 19/32

(365 days) 365X24 = 8760 hours.

or limited control (all products).

Copyright 2007-2009 Lafarge SA – DPC/ Confidential 20/32

MTBF 1-Quarry;2-Raw mix preparation;3-Burning;4-Finish Grinding

Copyright 2007-2009 Lafarge SA – DPC/ Confidential 21/32

Kiln level: PA019X / PR039X

exclude them in the calculation.